KitLog pro

Powered By Kitlog Pro v2.0

Zenith CruZer & Sonex Logs
' style=
Date:  5-5-2018
Number of Hours:  2.00
Manual Reference:  C75-KA-1
Brief Description:  Prep Right Wing Fuel Tank

I felt I've overcome a mental block, and made progress.

Not a block, but all week since my last accomplishment, the weather has been lousy. Super humid, cloudy, and 3 days of rain. Yeah, I'm in the garage, but it was just a blue-funk-inducing environment. Today was glorious, but I was apprehensive about installing the fuel sending unit.

The tank comes with fittings for everything - except the fuel sender. This has to have a 59 mm hole drilled in the side of the tank. With a fly-cutter. These things are notorious for ovalling a hole, so I practiced a bit the other day on spare sheet stock from my Sonex build. Can't really measure 28.5 mm on the fly cutter, so trial-and-error'd it until I got good results. When I measured the distance of the cutters, it showed 60 mm, whereas the hole it produced was much closer to 58. Close enough; I can always file it a bit. Thiere is just not that much space from the edge of the hole to the edge of the attachment screws.

I marked the location of the hole on the tank, and the actual cutting went better than I expected. The hole measured about 58.5 mm (need 59), so I played with the attachment ring a bit to get it to fit. Ground one area opposite the "notch", and filed a bit on the tank itself. Test fit was fine.

The sender is attached by a steel ring on the inside of the tank, then the tank, then a rubber washer, then the unit itself. You install one long screw to let you angle the inner ring, then tighten it up and install the other screws. Some builders have had leaks from the sender, so I wiped a thin film of teflon non-hardening fuel sealer on both sides of the gasket/washer. All appears to be good. Will leak test before installation.

One thing I skipped over is that the sender units are VW bug units; they must be modified to work in the shorter but wider wing tank. Fig 1 shows the bend (125 deg) spec'd by Zenith. Works just fine. I also tested the sending unit with a multimeter before installing - just to make sure.

Installed grounding wires, since
' style=

Modified sender unit on bottom; stock on top

Modified sender unit on bottom; stock on top

' style=

Installed sender unit; one wire to tank, one to fuse (grounds)

Installed sender unit; one wire to tank, one to fuse (grounds)

' style=

Right wingtip nav/pos/strobe wire tied to rear spar

Right wingtip nav/pos/strobe wire tied to rear spar

' style=










Copyright © 2001-2020 Matronics. All Rights Reserved.